Re: [Emc-users] Deep slot chip removal
With an open machine I tend to us air rf vacuum to extract chips. One needs enough air movement to get turbulence for effective chip removal. I tend to start pockets, etc with a drill to within .02 of full depth. I've also drilled a pattern of holes to extract major volumes of material from pockets. However, just getting a good starting hole with a drill and then continuing with a mill is a smoother process. In desperation mode blow air and catch the chips with vacuum much like a dentist does. Dave On 12/1/22 12:18 AM, Gregg Eshelman via Emc-users wrote: Flood coolant, air blowing, or vacuum. Or pre-drill a bunch of holes to almost finished depth to remove the majority of the waste before milling. On Wednesday, November 30, 2022 at 10:08:49 AM MST, Nicklas SB Karlsson wrote: Milling a deep pocket spiral down work great first turn but after a while torque is not enough and mill stop. Suspect it is because mill have to cut old chips in addition to machining part. Maybe it is a good idea to use drill bit a little bit smaller than slot? Nicklas Karlsson ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
If possible, I like to use a tool 1/2-1/3 of the width of the slot and use a HSM style milling path. I've cut 3/4" deep in a single pass in aluminum using a 1/4" bit to make a 1/2" wide slot this way. A strong air blast or flood coolant is essential to clear the chips. Used FreeCAD to generate the tool paths. It is called "Adaptive Clearing and Profiling" in the Path menu of FreeCAD. It is amazing the cuts you can make with this kind of strategy even with a low power spindle or router. The secret is that you are never engaging more than a small percentage of the cutting face of the tool at one time, vs the full diameter of the tool using a conventional slotting path. Todd Zuercher P. Graham Dunn Inc. 630 Henry Street Dalton, Ohio 44618 Phone: (330)828-2105ext. 2031 -Original Message- From: Nicklas SB Karlsson Sent: Thursday, December 01, 2022 4:07 AM To: emc-users@lists.sourceforge.net Subject: Re: [Emc-users] Deep slot chip removal [EXTERNAL EMAIL] Be sure links are safe. tor 2022-12-01 klockan 08:18 + skrev Gregg Eshelman via Emc-users: > Flood coolant, air blowing, or vacuum. Or pre-drill a bunch of holes > to almost finished depth to remove the majority of the waste before > milling. Got that. Then the only question left is if using a mill at least slightly smaller than slot then cutting a deep slot is a good idea. ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://nam04.safelinks.protection.outlook.com/?url=https%3A%2F%2Flists.sourceforge.net%2Flists%2Flistinfo%2Femc-usersdata=05%7C01%7Ctoddz%40pgrahamdunn.com%7C1a9e3f0cec294805660108dad37b9082%7C5758544c573f47cebee96c3e0806fb43%7C0%7C0%7C638054824905710770%7CUnknown%7CTWFpbGZsb3d8eyJWIjoiMC4wLjAwMDAiLCJQIjoiV2luMzIiLCJBTiI6Ik1haWwiLCJXVCI6Mn0%3D%7C3000%7C%7C%7Csdata=xZthFT91b7lDDWpzKyMw8zJmW2EDLdE2PW80h3GKnIs%3Dreserved=0 ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
Yes, you should mill slots with a slightly smaller cutter and cut slightly undersize. Then cut to the finished dimensions. That way during the finish pass only one side of the cutter is touching the work. Chips should be removed before the finish pass. Some people make one or two 'spring passes' after the finish pass, without changing the cut dimensions. Speed up the spindle a bit and/or slow the feed rate a little so the cuts per unit of distance are different and it'll nip off any slightly high spots as well as allow the tool and work to cut completely straight. The light load removes any deflection or 'spring' from the tool. On a lathe a piece can be cut to the correct dimension but the tool can still cut a small amount when making more passes without further advancing the tool. Slowing the feed rate and increasing the spindle speed on a spring pass can produce a smoother finish that still measures the correct dimension. But don't do it too much or the piece may end up too small. I've done that, though it's not as much of an issue with bigger, stiffer machines. On Thursday, December 1, 2022 at 02:08:31 AM MST, Nicklas SB Karlsson wrote: tor 2022-12-01 klockan 08:18 + skrev Gregg Eshelman via Emc-users: > Flood coolant, air blowing, or vacuum. Or pre-drill a bunch of holes > to almost finished depth to remove the majority of the waste before > milling. Got that. Then the only question left is if using a mill at least slightly smaller than slot then cutting a deep slot is a good idea. ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
tor 2022-12-01 klockan 08:18 + skrev Gregg Eshelman via Emc-users: > Flood coolant, air blowing, or vacuum. Or pre-drill a bunch of holes > to almost finished depth to remove the majority of the waste before > milling. Got that. Then the only question left is if using a mill at least slightly smaller than slot then cutting a deep slot is a good idea. ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
Spinlde size is around 8-9kW but currently limited to about 1/4 of the torque. 12mm tool milling a slot same with as tool. Changed program and will predrill thru holes first to help chip evacuation. This will solve the problem for this time but guess this is not the last time I machine a deep pocket. ons 2022-11-30 klockan 12:46 -0500 skrev Matthew Herd: > What size mill and tool are we talking about? Is this <1kW of > spindle > power? Is the tool <10mm? I'm a bit surprised that the spindle > would > stall due to uncut chips. > > On Wed, Nov 30, 2022 at 12:43 PM Nicklas SB Karlsson > wrote: > > > ons 2022-11-30 klockan 12:11 -0500 skrev Matthew Herd: > > > A drill for an entry hole is never a bad idea. Other options > > > include > > > using > > > a tool with a smaller diameter or fewer flutes. Can you improve > > > chip > > > evacuation? That's never a bad idea in any event. If feasible, > > > a > > > vacuum > > > or some repeated blasts with the air gun are helpful. Also, can > > > you > > > reduce > > > the ramp angle for the helix? > > Have no really good method to get the chip out of the slot though > > could > > stop and manually remove most of it and drill thru holes. Tried > > reducing the ramp angle but did not help or only a little bit. > > > > Smaller mill or first drilling thru holes is ideas I have. > > > > > > > > On Wed, Nov 30, 2022 at 12:09 PM Nicklas SB Karlsson > > > wrote: > > > > > > > Milling a deep pocket spiral down work great first turn but > > > > after a > > > > while torque is not enough and mill stop. Suspect it is because > > > > mill > > > > have to cut old chips in addition to machining part. > > > > > > > > Maybe it is a good idea to use drill bit a little bit smaller > > > > than > > > > slot? > > > > > > > > > > > > Nicklas Karlsson > > > > > > > > > > > > > > > > ___ > > > > Emc-users mailing list > > > > Emc-users@lists.sourceforge.net > > > > https://lists.sourceforge.net/lists/listinfo/emc-users > > > > > > > > > > > > > > > > > > > > ___ > > Emc-users mailing list > > Emc-users@lists.sourceforge.net > > https://lists.sourceforge.net/lists/listinfo/emc-users > > > > ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
Flood coolant, air blowing, or vacuum. Or pre-drill a bunch of holes to almost finished depth to remove the majority of the waste before milling. On Wednesday, November 30, 2022 at 10:08:49 AM MST, Nicklas SB Karlsson wrote: Milling a deep pocket spiral down work great first turn but after a while torque is not enough and mill stop. Suspect it is because mill have to cut old chips in addition to machining part. Maybe it is a good idea to use drill bit a little bit smaller than slot? Nicklas Karlsson ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
What size mill and tool are we talking about? Is this <1kW of spindle power? Is the tool <10mm? I'm a bit surprised that the spindle would stall due to uncut chips. On Wed, Nov 30, 2022 at 12:43 PM Nicklas SB Karlsson wrote: > ons 2022-11-30 klockan 12:11 -0500 skrev Matthew Herd: > > A drill for an entry hole is never a bad idea. Other options include > > using > > a tool with a smaller diameter or fewer flutes. Can you improve chip > > evacuation? That's never a bad idea in any event. If feasible, a > > vacuum > > or some repeated blasts with the air gun are helpful. Also, can you > > reduce > > the ramp angle for the helix? > Have no really good method to get the chip out of the slot though could > stop and manually remove most of it and drill thru holes. Tried > reducing the ramp angle but did not help or only a little bit. > > Smaller mill or first drilling thru holes is ideas I have. > > > > > On Wed, Nov 30, 2022 at 12:09 PM Nicklas SB Karlsson > > wrote: > > > > > Milling a deep pocket spiral down work great first turn but after a > > > while torque is not enough and mill stop. Suspect it is because > > > mill > > > have to cut old chips in addition to machining part. > > > > > > Maybe it is a good idea to use drill bit a little bit smaller than > > > slot? > > > > > > > > > Nicklas Karlsson > > > > > > > > > > > > ___ > > > Emc-users mailing list > > > Emc-users@lists.sourceforge.net > > > https://lists.sourceforge.net/lists/listinfo/emc-users > > > > > > > > > > > > ___ > Emc-users mailing list > Emc-users@lists.sourceforge.net > https://lists.sourceforge.net/lists/listinfo/emc-users > -- Matthew Herd Email: herd.m...@gmail.com Cell: 610-608-8930 ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
ons 2022-11-30 klockan 12:11 -0500 skrev Matthew Herd: > A drill for an entry hole is never a bad idea. Other options include > using > a tool with a smaller diameter or fewer flutes. Can you improve chip > evacuation? That's never a bad idea in any event. If feasible, a > vacuum > or some repeated blasts with the air gun are helpful. Also, can you > reduce > the ramp angle for the helix? Have no really good method to get the chip out of the slot though could stop and manually remove most of it and drill thru holes. Tried reducing the ramp angle but did not help or only a little bit. Smaller mill or first drilling thru holes is ideas I have. > > On Wed, Nov 30, 2022 at 12:09 PM Nicklas SB Karlsson > wrote: > > > Milling a deep pocket spiral down work great first turn but after a > > while torque is not enough and mill stop. Suspect it is because > > mill > > have to cut old chips in addition to machining part. > > > > Maybe it is a good idea to use drill bit a little bit smaller than > > slot? > > > > > > Nicklas Karlsson > > > > > > > > ___ > > Emc-users mailing list > > Emc-users@lists.sourceforge.net > > https://lists.sourceforge.net/lists/listinfo/emc-users > > > > ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
Re: [Emc-users] Deep slot chip removal
A drill for an entry hole is never a bad idea. Other options include using a tool with a smaller diameter or fewer flutes. Can you improve chip evacuation? That's never a bad idea in any event. If feasible, a vacuum or some repeated blasts with the air gun are helpful. Also, can you reduce the ramp angle for the helix? On Wed, Nov 30, 2022 at 12:09 PM Nicklas SB Karlsson wrote: > Milling a deep pocket spiral down work great first turn but after a > while torque is not enough and mill stop. Suspect it is because mill > have to cut old chips in addition to machining part. > > Maybe it is a good idea to use drill bit a little bit smaller than > slot? > > > Nicklas Karlsson > > > > ___ > Emc-users mailing list > Emc-users@lists.sourceforge.net > https://lists.sourceforge.net/lists/listinfo/emc-users > -- Matthew Herd Email: herd.m...@gmail.com Cell: 610-608-8930 ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
[Emc-users] Deep slot chip removal
Milling a deep pocket spiral down work great first turn but after a while torque is not enough and mill stop. Suspect it is because mill have to cut old chips in addition to machining part. Maybe it is a good idea to use drill bit a little bit smaller than slot? Nicklas Karlsson ___ Emc-users mailing list Emc-users@lists.sourceforge.net https://lists.sourceforge.net/lists/listinfo/emc-users
